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NASA NTRS2002

Slow Crack Growth of Brittle Materials With Exponential Crack-Velocity Formulation: Constant Stress and Cyclic Stress Experiments - Part 3

The previously determined life prediction analysis based on an exponential crack-velocity formulation was examined using a variety of experimental data on advanced structural ceramics tested under constant stress and cyclic stress loading at ambient and elevated temperatures. The data fit to the relation between the time to failure and applied stress (or maximum applied stress in cyclic loading) was very reasonable for most of the materials studied. It was also found that life prediction for cyclic stress loading from data of constant stress loading in the exponential formulation was in good agreement with the experimental data, resulting in a similar degree of accuracy as compared with the power-law formulation. The major limitation in the exponential crack-velocity formulation, however, was that the inert strength of a material must be known a priori to evaluate the important slow-crack-growth (SCG) parameter n, a significant drawback as compared with the conventional power-law crack-velocity formulation.

Choi, Sung R.↗

NASA NTRS2003

Long-Term Reliability of High Speed SiGe/Si Heterojunction Bipolar Transistors

Accelerated lifetime tests were performed on double-mesa structure Si/Si0.7Ge0.3/Si npn heterojunction bipolar transistors, grown by molecular beam epitaxy, in the temperature range of 175C-275C. Both single- and multiple finger transistors were tested. The single-finger transistors (with 5x20 micron sq m emitter area) have DC current gains approximately 40-50 and f(sub T) and f(sub MAX) of up to 22 GHz and 25 GHz, respectively. The multiple finger transistors (1.4 micron finger width, 9 emitter fingers with total emitter area of 403 micron sq m) have similar DC current gain but f(sub T) of 50 GHz. It is found that a gradual degradation in these devices is caused by the recombination enhanced impurity diffusion (REID) of boron atoms from the p-type base region and the associated formation of parasitic energy barriers to electron transport from the emitter to collector layers. This REID has been quantitatively modeled and explained, to the first order of approximation, and the agreement with the measured data is good. The mean time to failure (MTTF) of the devices at room temperature is estimated from the extrapolation of the Arrhenius plots of device lifetime versus reciprocal temperature. The results of the reliability tests offer valuable feedback for SiGe heterostructure design in order to improve the long-term reliability of the devices and circuits made with them. Hot electron induced degradation of the base-emitter junction was also observed during the accelerated lifetime testing. In order to improve the HBT reliability endangered by the hot electrons, deuterium sintered techniques have been proposed. The preliminary results from this study show that a deuterium-sintered HBT is, indeed, more resistant to hot-electron induced base-emitter junction degradation. SiGe/Si based amplifier circuits were also subjected to lifetime testing and we extrapolate MTTF is approximately 1.1_10(exp 6) hours at 125iC junction temperature from the circuit lifetime data.

Ponchak, George E.↗

NASA NTRS2003

NASA Helps Keep the Light Burning for the Saturn Car Company

The Saturn Electronics & Engineering, Inc. (Saturn) facility in Marks, Miss., that produces lamp assemblies was experiencing itermittent problems with its automotive under the hood lamps. After numerous testing and engineering efforts, technicians could not pin down the root of the problem. So Saturn contacted the NASA Technology Assistance Program (TAP) at Stennis Space Center. The Marks production facility had been experiencing intermittent problems with under the hood lamp assemblies for some time. The failure rate, at 2 percent, was unacceptable. Every effort was made to identify the problem so that corrective action could be put in place. The problem was investigated and researched by Saturn's engineering department. In addition, Saturn brought in several independent testing laboratories. Other measures included examining the switch component suppliers and auditing them for compliance to the design specifications and for surface contaminants. All attempts to identify the factors responsible for the failures were inconclusive. In an effort to get to the root of the problem, and at the recommendation of the Mississippi Department of Economic Development, Saturn contacted the NASA TAP at Stennis. The NASA Materials and Contamination Laboratory, with assistance from the Stennis Prototype Laboratory, conducted a materials evaluation study on the switch components. The laboratory findings showed the failures were caused by a build-up of carbon-based contaminants on the switch components. Saturn Electronics & Engineering, Inc., is a minority-owned provider of contract manufacturing services to a diverse global marketplace. Saturn operates manufacturing facilities globally serving the North American, European, and Asian markets. Saturn's production facility in Marks, Mississippi, produces more than 1,000,000 lamps and switches monthly. "Since the NASA recommendations were implemented, our internal failure rate for intermittency has dropped to less than .02 percent. Most importantly, we restored our high-level of customer satisfaction. Stennis provided an invaluable service to our business," Patrick said. Both NASA and Saturn were pleased with the results form this technical assistance project. The Technology Assistance Program at Stennis makes available to the public NASA technical expertise and access to lab facilities. This project provided both services with a positive outcome.

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NASA NTRS1999

The NOAA-9 Earth Radiation Budget Experiment Wide Field-of-View Data Set

The Earth Radiation Budget Experiment (ERBE) consisted of wide field-of-view (WFOV) radiometers and scanning radiometers for measuring outgoing longwave radiation and solar radiation reflected from the Earth. These instruments were carried by the dedicated Earth Radiation Budget Satellite (ERBS) and by the NOAA-9 and -10 operational spacecraft. The WFOV radiometers provided data from which instantaneous fluxes at the top of the atmosphere (TOA) are computed by use of a numerical filter algorithm. Monthly mean fluxes over a 5-degree equal angle grid are computed from the instantaneous TOA fluxes. The WFOV radiometers aboard the NOAA-9 spacecraft operated from February 1985 through December 1992, at which time a failure of the shortwave radiometer ended the usable data after nearly 8 years. This paper examines the monthly mean products from that data set.

Bush, Kathryn A.↗

NASA NTRS1998

Aerospace Applications of Weibull and Monte Carlo Simulation with Importance Sampling

Recent developments in reliability modeling and computer technology have made it practical to use the Weibull time to failure distribution to model the system reliability of complex fault-tolerant computer-based systems. These system models are becoming increasingly popular in space systems applications as a result of mounting data that support the decreasing Weibull failure distribution and the expectation of increased system reliability. This presentation introduces the new reliability modeling developments and demonstrates their application to a novel space system application. The application is a proposed guidance, navigation, and control (GN&C) system for use in a long duration manned spacecraft for a possible Mars mission. Comparisons to the constant failure rate model are presented and the ramifications of doing so are discussed.

Bavuso, Salvatore J.↗

NASA NTRS2005

An Evaluation of the Applicability of Damage Tolerance to Dynamic Systems

The Federal Aviation Administration, the National Aeronautics and Space Administration and the aircraft industry have teamed together to develop methods and guidance for the safe life-cycle management of dynamic systems. Based on the success of the United States Air Force damage tolerance initiative for airframe structure, a crack growth based damage tolerance approach is being examined for implementation into the design and management of dynamic systems. However, dynamic systems accumulate millions of vibratory cycles per flight hour, more than 12,000 times faster than an airframe system. If a detectable crack develops in a dynamic system, the time to failure is extremely short, less than 100 flight hours in most cases, leaving little room for error in the material characterization, life cycle analysis, nondestructive inspection and maintenance processes. In this paper, the authors review the damage tolerant design process focusing on uncertainties that affect dynamic systems and evaluate the applicability of damage tolerance on dynamic systems.

Forth, Scott C.↗

NASA NTRS1996

Integrated Design Software Predicts the Creep Life of Monolithic Ceramic Components

Significant improvements in propulsion and power generation for the next century will require revolutionary advances in high-temperature materials and structural design. Advanced ceramics are candidate materials for these elevated-temperature applications. As design protocols emerge for these material systems, designers must be aware of several innate features, including the degrading ability of ceramics to carry sustained load. Usually, time-dependent failure in ceramics occurs because of two different, delayedfailure mechanisms: slow crack growth and creep rupture. Slow crack growth initiates at a preexisting flaw and continues until a critical crack length is reached, causing catastrophic failure. Creep rupture, on the other hand, occurs because of bulk damage in the material: void nucleation and coalescence that eventually leads to macrocracks which then propagate to failure. Successful application of advanced ceramics depends on proper characterization of material behavior and the use of an appropriate design methodology. The life of a ceramic component can be predicted with the NASA Lewis Research Center's Ceramics Analysis and Reliability Evaluation of Structures (CARES) integrated design programs. CARES/CREEP determines the expected life of a component under creep conditions, and CARES/LIFE predicts the component life due to fast fracture and subcritical crack growth. The previously developed CARES/LIFE program has been used in numerous industrial and Government applications.

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NASA NTRS2003

Oxidation of Carbon Fibers in Water Vapor Studied

T-300 carbon fibers (BP Amoco Chemicals, Greenville, SC) are a common reinforcement for silicon carbide composite materials, and carbon-fiber-reinforced silicon carbide composites (C/SiC) are proposed for use in space propulsion applications. It has been shown that the time to failure for C/SiC in stressed oxidation tests is directly correlated with the fiber oxidation rate (ref. 1). To date, most of the testing of these fibers and composites has been conducted in oxygen or air environments; however, many components for space propulsion, such as turbopumps, combustors, and thrusters, are expected to operate in hydrogen and water vapor (H2/H2O) environments with very low oxygen contents. The oxidation rate of carbon fibers in conditions representative of space propulsion environments is, therefore, critical for predicting component lifetimes for real applications. This report describes experimental results that demonstrate that, under some conditions, lower oxidation rates of carbon fibers are observed in water vapor and H2/H2O environments than are found in oxygen or air. At the NASA Glenn Research Center, the weight loss of the fibers was studied as a function of water pressure, temperature, and gas velocity. The rate of carbon fiber oxidation was determined, and the reaction mechanism was identified.

Opila, Elizabeth J.↗

NASA NTRS2008

Exploration Technology Developments Program's Radiation Hardened Electronics for Space Environments (RHESE) Project Overview

Primary Objective: 1) A computational tool to accurately predict electronics performance in the presence of space radiation in support of spacecraft design: a) Total dose; b) Single Event Effects; and c) Mean Time Between Failure. (Developed as successor to CR ME96.) Secondary Objectives: 2) To provide a detailed description of the natural radiation environment in support of radiation health and instrument design: a) In deep space; b) Inside the magnetosphere; and c) Behind shielding.

Keys, Andrew S.↗

NASA NTRS2008

Mars Reconnaissance Orbiter In-flight Anomalies and Lessons Learned: An Update

The Mars Reconnaissance Orbiter mission has as its primary objectives: advance our understanding of the current Mars climate, the processes that have formed and modified the surface of the planet and the extent to which water has played a role in surface processes; identify sites of possible aqueous activity indicating environments that may have been or are conducive to biological activity; and thus identify and characterize sites for future landed missions; and provide forward and return relay services for current and future Mars landed assets. MRO's crucial role in the long term strategy for Mars exploration requires a high level of reliability during its 5.4 year mission. This requires an architecture which incorporates extensive redundancy and cross-strapping. Because of the distances and hence light-times involved, the spacecraft itself must be able to utilize this redundancy in responding to time-critical failures. For cases where fault protection is unable to recognize a potentially threatening condition, either due to known limitations or software flaws, intervention by ground operations is required. These aspects of MRO's design were discussed in a previous paper [Ref. 1]. This paper provides an update to the original paper, describing MRO's significant in-flight anomalies over the past year, with lessons learned for redundancy and fault protection architectures and for ground operations.

Mars Reconnaissance Orbiter↗

NASA NTRS2005

Diagnosis and Prognosis of Weapon Systems

The Prognostics Framework is a set of software tools with an open architecture that affords a capability to integrate various prognostic software mechanisms and to provide information for operational and battlefield decision-making and logistical planning pertaining to weapon systems. The Prognostics NASA Tech Briefs, February 2005 17 Framework is also a system-level health -management software system that (1) receives data from performance- monitoring and built-in-test sensors and from other prognostic software and (2) processes the received data to derive a diagnosis and a prognosis for a weapon system. This software relates the diagnostic and prognostic information to the overall health of the system, to the ability of the system to perform specific missions, and to needed maintenance actions and maintenance resources. In the development of the Prognostics Framework, effort was focused primarily on extending previously developed model-based diagnostic-reasoning software to add prognostic reasoning capabilities, including capabilities to perform statistical analyses and to utilize information pertaining to deterioration of parts, failure modes, time sensitivity of measured values, mission criticality, historical data, and trends in measurement data. As thus extended, the software offers an overall health-monitoring capability.

Nolan, Mary↗

NASA NTRS2004

Updated System-Availability and Resource-Allocation Program

A second version of the Availability, Cost and Resource Allocation (ACARA) computer program has become available. The first version was reported in an earlier tech brief. To recapitulate: ACARA analyzes the availability, mean-time-between-failures of components, life-cycle costs, and scheduling of resources of a complex system of equipment. ACARA uses a statistical Monte Carlo method to simulate the failure and repair of components while complying with user-specified constraints on spare parts and resources. ACARA evaluates the performance of the system on the basis of a mathematical model developed from a block-diagram representation. The previous version utilized the MS-DOS operating system and could not be run by use of the most recent versions of the Windows operating system. The current version incorporates the algorithms of the previous version but is compatible with Windows and utilizes menus and a file-management approach typical of Windows-based software.

Viterna, Larry↗

NASA NTRS2014

Evaluation of Commercial Automotive-Grade BME Capacitors

Three Ni-BaTiO3 ceramic capacitor lots with the same specification (chip size, capacitance, and rated voltage) and the same reliability level, made by three different manufacturers, were degraded using highly accelerated life stress testing (HALST) with the same temperature and applied voltage conditions. The reliability, as characterized by mean time to failure (MTTF), differed by more than one order of magnitude among the capacitor lots. A theoretical model based on the existence of depletion layers at grain boundaries and the entrapment of oxygen vacancies has been proposed to explain the MTTF difference among these BME capacitors. It is the conclusion of this model that reliability will not be improved simply by increasing the insulation resistance of a BME capacitor. Indeed, Ni-BaTiO3 ceramic capacitors with a smaller degradation rate constant K will always give rise to a longer reliability life

capacitor↗

NASA NTRS2014

Evaluation of Commercial Automotive-Grade BME Capacitors

reliability↗

NASA NTRS2014

Solid Rocket Launch Vehicle Explosion Environments

Empirical explosion data from full scale solid rocket launch vehicle accidents and tests were collected from all available literature from the 1950s to the present. In general data included peak blast overpressure, blast impulse, fragment size, fragment speed, and fragment dispersion. Most propellants were 1.1 explosives but a few were 1.3. Oftentimes the data from a single accident was disjointed and/or missing key aspects. Despite this fact, once the data as a whole was digitized, categorized, and plotted clear trends appeared. Particular emphasis was placed on tests or accidents that would be applicable to scenarios from which a crew might need to escape. Therefore, such tests where a large quantity of high explosive was used to initiate the solid rocket explosion were differentiated. Also, high speed ground impacts or tests used to simulate such were also culled. It was found that the explosions from all accidents and applicable tests could be described using only the pressurized gas energy stored in the chamber at the time of failure. Additionally, fragmentation trends were produced. Only one accident mentioned the elusive "small" propellant fragments, but upon further analysis it was found that these were most likely produced as secondary fragments when larger primary fragments impacted the ground. Finally, a brief discussion of how this data is used in a new launch vehicle explosion model for improving crew/payload survival is presented.

Richardson, E. H.↗

NASA NTRS2015

A Metric to Quantify Shared Visual Attention in Two-Person Teams

Introduction: Critical tasks in high-risk environments are often performed by teams, the members of which must work together efficiently. In some situations, the team members may have to work together to solve a particular problem, while in others it may be better for them to divide the work into separate tasks that can be completed in parallel. We hypothesize that these two team strategies can be differentiated on the basis of shared visual attention, measured by gaze tracking. 2) Methods: Gaze recordings were obtained for two-person flight crews flying a high-fidelity simulator (Gontar, Hoermann, 2014). Gaze was categorized with respect to 12 areas of interest (AOIs). We used these data to construct time series of 12 dimensional vectors, with each vector component representing one of the AOIs. At each time step, each vector component was set to 0, except for the one corresponding to the currently fixated AOI, which was set to 1. This time series could then be averaged in time, with the averaging window time (t) as a variable parameter. For example, when we average with a t of one minute, each vector component represents the proportion of time that the corresponding AOI was fixated within the corresponding one minute interval. We then computed the Pearson product-moment correlation coefficient between the gaze proportion vectors for each of the two crew members, at each point in time, resulting in a signal representing the time-varying correlation between gaze behaviors. We determined criteria for concluding correlated gaze behavior using two methods: first, a permutation test was applied to the subjects' data. When one crew member's gaze proportion vector is correlated with a random time sample from the other crewmember's data, a distribution of correlation values is obtained that differs markedly from the distribution obtained from temporally aligned samples. In addition to validating that the gaze tracker was functioning reasonably well, this also allows us to compute probabilities of coordinated behavior for each value of the correlation. As an alternative, we also tabulated distributions of correlation coefficients for synthetic data sets, in which the behavior was modeled as a first-order Markov process, and compared correlation distributions for identical processes with those for disparate processes, allowing us to choose criteria and estimate error rates. 3) Discussion: Our method of gaze correlation is able to measure shared visual attention, and can distinguish between activities involving different instruments. We plan to analyze whether pilots strategies of sharing visual attention can predict performance. Possible measurements of performance include expert ratings from instructors, fuel consumption, total task time, and failure rate. While developed for two-person crews, our approach can be applied to larger groups, using intra-class correlation coefficients instead of the Pearson product-moment correlation.

Gontar, Patrick↗

NASA NTRS2017

Real-Time Risk Assessment Framework for Unmanned Aircraft System (UAS) Traffic Management (UTM)

The new Federal Aviation Administration (FAA) Small Unmanned Aircraft rule (Part 107) marks the first national regulations for commercial operation of small unmanned aircraft systems (sUAS) under 55 pounds within the National Airspace System (NAS). Although sUAS flights may not be performed beyond visual line-of-sight or over non- participant structures and people, safety of sUAS operations must still be maintained and tracked at all times. Moreover, future safety-critical operation of sUAS (e.g., for package delivery) are already being conceived and tested. NASA's Unmanned Aircraft System Trac Management (UTM) concept aims to facilitate the safe use of low-altitude airspace for sUAS operations. This paper introduces the UTM Risk Assessment Framework (URAF) which was developed to provide real-time safety evaluation and tracking capability within the UTM concept. The URAF uses Bayesian Belief Networks (BBNs) to propagate off -nominal condition probabilities based on real-time component failure indicators. This information is then used to assess the risk to people on the ground by calculating the potential impact area and the effects of the impact. The visual representation of the expected area of impact and the nominal risk level can assist operators and controllers with dynamic trajectory planning and execution. The URAF was applied to a case study to illustrate the concept.

Ancel, Ersin↗

NASA NTRS2017

Hybrid Gear Performance Under Loss-of-Lubrication Conditions

Hybrid composite gear technology is being investigated to increase power density in rotorcraft drive systems. These gears differ from conventional steel gears in that the structural web material is replaced with a lightweight carbon fiber composite. Past studies have focused on performance of this technology under normal operating conditions, however, for this technology to be viable it must also withstand adverse conditions. The study presented here evaluates the performance of hybrid gears under loss-of-lubrication conditions in NASA Glenn Research Centers Contact Fatigue Test Facility. Two experiments are presented using small-scale 3.5 inch (8.9 cm) pitch diameter hybrid gears and compared to a baseline steel gear pair. Results of these tests show that there are limitations to the use of a hexagonal interlock pattern between the steel and composite. There is also evidence that the presence of polymer in the gear during an oil out event has a potential to increase time to failure. Further studies are planned to expand on these initial findings.

Gearbox↗